Study of Alternative Lubricants for Cold Extrusion Process of A1100 Pure Aluminum

2014 ◽  
Vol 71 (2) ◽  
Author(s):  
A. Nurul M. ◽  
Syahrullail S.
Keyword(s):  
Renewable Resources ◽  
Pure Aluminum ◽  
Cold Work ◽  
Palm Kernel ◽  
Palm Stearin ◽  
Mineral Oil ◽  
Cold Extrusion ◽  
Film Material ◽  
Ability To Act ◽  
Taper Die

Lubrication in metal forming process is very important to control wear and friction at the interface between interacting surfaces. Non-renewable resources, such as mineral oil are widely used since a beginning due to its ability to act as a supplier to the wearing contact which functions as a film material or sustains chemical transformation to become a film material. Since it is will not last for a few more decades, renewable resources had been studied in order to find an alternative lubricant with presents similar results in terms of extrusion load and product quality. Two renewable lubricants were analyzed (Palm Kernel and Palm Stearin) together with additive free paraffinic mineral oil VG460 will act as a comparison lubricant. The experiment used a cold work plane strain extrusion apparatus consisting of a pair of taper die and a symmetrical work piece (billet). The billet material was annealed pure aluminum A1100 with radius of 5mm at the deformation area. It was found that palm Palm Kernel and Palm Stearin performed slightly high extrusion load, however they show no severe wear on product surface. Based on the results, it is proven that renewable based lubricants can be considered as a substitute to common mineral based lubricants used in the industry.

DETERMINING ALTERNATIVES FOR METAL FORMING LUBRICANTS: A STUDY USING PLANE STRAIN COLD EXTRUSION PROCESS OF JIS-A1100 PURE ALUMINUM BILLET

2015 ◽  
Vol 74 (10) ◽  
Author(s):  
M. A. Nurul ◽  
S. Syahrullail ◽  
M. N. Musa
Keyword(s):  
Product Quality ◽  
Plane Strain ◽  
Renewable Resources ◽  
Metal Forming ◽  
Pure Aluminum ◽  
Cold Work ◽  
Cold Extrusion ◽  
Film Material ◽  
Ability To Act ◽  
Taper Die

Lubrication is very important in metal forming processes to control wear and friction at the interface between interacting surfaces. Non-renewable resources, such as plain mineral oils are widely used due to its ability to act as a supplier to wearing contacts; it may function as a film material or even sustain chemical transformations to become a film material. Since non-renewable resources can only last for more than a decade, renewable resources have been studied in order to find alternative lubricants that can present similar results in terms of extrusion load and product quality. Two renewable lubricants were analyzed (RBD palm olein and jatropha) together with an additive free paraffinic mineral oil, VG32, which acted as a reference lubricant. The experiment used a cold work plane strain extrusion apparatus that consists of a pair of taper die and a symmetrical work piece (billet). The billet material was made of annealed pure aluminum JIS-A1100 with radius of 5 mm in the deformation area. It was found that higher viscosity lubricants produced low extrusion load and friction during metal forming process with no major severe wear on product quality. Based on the results, it was proven that renewable resource based lubricants can be considered as a substitute for common lubricants used in the industry, since they present similar results with those currently applied in the industry. 

Evaluation of Paraffinic Mineral Oil as Lubricant in Cold Work Extrusion Process

2014 ◽  
Vol 554 ◽  
pp. 327-331 ◽  
Author(s):  
Samion Syahrullail ◽  
Mohd Ahyan Nurul Aini
Keyword(s):  
Plane Strain ◽  
Pure Aluminum ◽  
Cold Work ◽  
Extrusion Process ◽  
Mineral Oil ◽  
Experimental Result ◽  
Friction Effect ◽  
Billet Material ◽  
Deformation Area ◽  
Taper Die

In this paper, the effect of frictional constraint from the application of three different viscosity of additive free paraffinic mineral oil as lubricant were investigated by cold work forward plane strain extrusion experiments. The experiment used a cold work plane strain extrusion apparatus consist of a pair of taper die and a symmetrical workpiece (billet). The billet material was annealed pure aluminum A1100 with radius 5 mm in deformation area. The experimental result shows that the higher viscosity, will lead to lower friction effect to the deformed area, as well as product area.

THE EFFECTS OF THE DIE HALF ANGLE OF TAPER DIE ON PLANE STRAIN EXTRUSION

2016 ◽  
Vol 78 (9-2) ◽  
Author(s):  
A. M. S. Zuan ◽  
S. Y. Yong ◽  
M. A. Nurul ◽  
S. Syahrullail ◽  
E. A. Rahim
Keyword(s):  
Surface Roughness ◽  
Relative Velocity ◽  
Palm Stearin ◽  
Extrusion Process ◽  
Mineral Oil ◽  
Comparison Study ◽  
Taper Angle ◽  
Workpiece Surface ◽  
Half Angle ◽  
Taper Die

In this research, a study of the effect of a die half angle on the extrusion process has been performed. The experiments were conducted at room temperature around 27 °C. Two types of taper die with different die half angles (45° and 60°) were prepared. The test lubricants used were paraffinic mineral oil VG460 and Refined, Bleached and Deodorized (RBD) Palm stearin. The material of the workpiece (billet) was annealed with A1100 aluminium. The experimental results were focused on the extrusion load, tool and workpiece surface roughness and plastic deformation of the workpiece. The resultant relative velocity was calculated using a visioplasticity method. The results shows that a taper angle of 60° recorded higher resultant relative velocity with a lower extrusion load and surface roughness compare to the taper angle of 45°. The comparison study between Paraffinic Mineral Oil and RBD Palm Stearin shows no significant effect in both taper angles tested.

Alternative Lubricants: Study on Plant-Based Lubricants in Metal Forming Process

2016 ◽  
Vol 819 ◽  
pp. 469-473
Author(s):  
M.A. Nurul ◽  
Samion Syahrullail
Keyword(s):  
Pure Aluminum ◽  
Cold Work ◽  
Viscosity Index ◽  
Experimental Result ◽  
Forming Process ◽  
Lower Viscosity ◽  
Experimental Apparatus ◽  
Billet Material ◽  
Metal Forming Process ◽  
Taper Die

In this paper, the effect of metal-to-metal contact from the application of plant-based lubricants, RBD palm olein and jatropa were investigated by cold work forward plane strain extrusion experiments. A pair of taper die and a symmetrical workpiece (billet) was placed inside extrusion rig which acted as main experimental apparatus. The billet material was annealed pure aluminum A1100 with radius 5 mm in deformation area. The experimental result shows that the lower viscosity index, will lead to lower friction effect to the deformed area, as well as product area.

INVESTIGATION OF MICRO-PITS FORMATION ON BILLET SURFACES IN PLANE STRAIN EXTRUSION

2016 ◽  
Vol 78 (10-2) ◽  
Author(s):  
I. M. Izhan ◽  
S. Syahrullail ◽  
S. Y. Yong ◽  
M. A. Nurul
Keyword(s):  
Surface Roughness ◽  
Cross Section ◽  
Room Temperature ◽  
Palm Stearin ◽  
Mineral Oil ◽  
Tribological Performance ◽  
Work Piece ◽  
Half Angle ◽  
Plain Strain ◽  
Taper Die

Extrusion is a process of pushing a material through a die to yield a desired cross-section product. The application of surface texture has become well known for enhancing tribological performance. In this research, the effect of micro-pits embedded on a work piece lubricated with vegetable oil using plain strain extrusion were studied and compared with those seen with mineral-based oil lubricant. The experiments were conducted at room temperature (around 27℃). A taper die with a 60 die half-angle, with micro-pits array, was prepared. Test lubricants used were paraffinic mineral oil (PMO) VG460 and VG95 and refined, bleached and deodorized (RBD) palm stearin. The results were analysed to determine the extrusion load and the billet’s surface roughness and plastic deformation. RBD palm stearin was recorded as having the highest extrusion load (83.15 kN).

UNS T30407

Alloy Digest ◽  
1985 ◽  
Vol 34 (4) ◽  
Keyword(s):  
Tool Steel ◽  
Vanadium Carbide ◽  
Cold Work ◽  
Heat Treating ◽  
Cold Extrusion ◽  
High Carbon ◽  
Extrusion Dies ◽  
Steel Mills ◽  
Aisi Type ◽  
Cold Work Tool Steel

Abstract UNS No. T30407 is a high-carbon chromium cold-work tool steel containing vanadium (4.0%) and molybdenum (1.0%). Its carbon and vanadium form a vanadium carbide that provides war resistance many times greater than that of UNS No. T30403 (AISI Type D3). UNS No. T30407 was developed for applications where extreme abrasive wear is needed. Its many applications include briquetting dies and punches, brick mold liners, pottery, tools, broaches, meat-chopper plates and cold-extrusion dies. This datasheet provides information on composition, physical properties, hardness, and elasticity. It also includes information on forming, heat treating, and machining. Filing Code: TS-439. Producer or source: Tool steel mills.

Investigation of the Suitability of Surface Treatments for Dry Cold Extrusion by Process-Oriented Tribological Testing

2015 ◽  
Vol 651-653 ◽  
pp. 473-479 ◽  
Author(s):  
Marco Teller ◽  
Markus Bambach ◽  
Gerhard Hirt ◽  
Ingo Ross ◽  
André Temmler ◽  
...  
Keyword(s):  
Metal Forming ◽  
Adhesive Wear ◽  
Pure Aluminum ◽  
Surface Treatments ◽  
Cold Extrusion ◽  
Workpiece Material ◽  
Initial Yield Stress ◽  
First Results ◽  
Tailored Surfaces ◽  
Steel Aisi

In cold extrusion of aluminum alloys adhesive wear can be prevented by an excessive lubrication of the process. While this causes additional process steps also environmental risks have to be addressed. Hence, dry metal forming, i.e. avoiding lubrication by means of coatings and topography modifications is highly desirable. In this paper first results concerning the behavior of tailored surfaces under dry metal forming conditions for pure aluminum are presented. Different surface treatments (laser polishing and Mo2BC coating) of the tool steel AISI H11 are tested in a compression-torsion-tribometer under conditions adapted from cold extrusion. Normal stresses six times higher than the initial yield stress of the tested workpiece material pure aluminum (AA1050-O) are applied. Furthermore, a strategy for the characterization of aluminum adhesions to the tool is introduced. The influences of different topographies and the presence of a coating on the loss of material due to adhesive wear are investigated.

Sign in / Sign up

Export Citation Format

Share Document